W. R. Grace Co.-Conn.

Andrew G Singleton

Michael D Jensen

Demetrius Michos

John R McCauley

Stephen Raymond Schmidt

Michael J Elder

John Henry Hain, Jr

Patrick J Kerwin

Fengjun Hua

John Robert Mccauley

Catalyst support-activator for olefin polymerization catalysts, and processes for making, the support-activator comprising an intercalated, modified and calcined smectite clay comprising (a) pillars comprising aluminum and optionally: (i) at least one rare earth or lanthanide group metal; or (ii) at least one rare earth or lanthanide group metal and gallium; and (b) at least one ion-exchanged metal ion selected from the group consisting of aluminum, barium, beryllium, calcium, cerium, cesium, copper, chromium, gadolinium, gallium, germanium, hafnium, holmium, iron (II and III), lanthanum, lithium, magnesium, manganese, neodymium, potassium, praseodymium, rubidium, samarium, silver, selenium, sodium, strontium, tellurium, terbium, thallium, thorium, tin, titanium, uranium, ytterbium, yttrium, zinc and zirconium. The pillared clay exhibits a basal dspacing of: (A) 9 to 18 angstroms; or (B) equal to or greater than about 18.5 angstroms. Use of the modified clays, with metallocene catalyst precursor components, provides active olefin polymerization catalysts, preferably in the substantial absence of aluminoxanes or boron-containing compounds.

Process to produce modified clay, supported metallocene polymerization catalyst

An intercalated, modified and calcined smectite clay comprising (a) pillars comprising aluminum and: (i) at least one rare earth or lanthanide group metal; or (ii) at least one rare earth or lanthanide group metal and gallium; and (b) at least one ion-exchanged metal selected from the group consisting of aluminum, barium, beryllium, calcium, cerium, cesium, copper, chromium, gadolinium, gallium, germanium, hafnium, holmium, iron (II and III), lanthanum, lithium, magnesium, manganese, neodymium, potassium, praseodymium, rubidium, samarium, silver, selenium, sodium, strontium, tellurium, terbium, thallium, thorium, tin, titanium, uranium, ytterbium, yttrium, zinc and zirconium; wherein the clay is characterized by a basal dspacing equal to or greater than about 18.5 angstroms; and processes for making. The modified clays are suitably used as catalyst support-activators and when used in combination with metallocene catalyst precursor components, can provide active catalysts for polymerizing at least one olefin, preferably in the substantial absence of aluminoxanes or boron-containing compounds.

Process to produce modified clay, modified clay produced and use thereof

Olefin polymerization catalysts or catalyst systems comprising a mixture, contact product, reaction product or complex comprising as elements or components: (A) at least one metallocene pre-catalyst compound or polymerization active metallocene compound; (B) at least one titanium containing metallocene compound; and when (A) is a metallocene pre-catalyst compound, (C) at least one activator; provided however: (I) the titanium-containing metallocene compound is inactive or substantially inactive for the polymerization of olefins prior to or concurrently with the use of the catalyst system for olefin polymerization. Also disclosed are processes for producing the catalyst system and polyolefins having desirable combinations of properties, including melt index and molecular weight distribution, which properties are particularly desirable for the manufacture of polyolefin film products, especially LLDPE film A preferred catalyst comprises a zirconium or hafnium metal containing metallocene, an inactivated titanocene and a SiO2 support carrier.

Process of making modified metallocene catalyst, catalyst produced and use thereof

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Ellicott City, MD, United States of America

Andrew G Singleton